Blank for a lightweight casket

ABSTRACT

The present invention is directed to a blank for folding into a body containment section of a casket, the blank comprising: a first stabilizing surface element, the first stabilizing surface element being a unitary element, a second stabilizing surface element positioned to lie above the first stabilizing surface element and spaced-apart therefrom, the second stabilizing surface element being a unitary element, and a core having a top surface and a bottom surface, the core being sandwiched between the first and second stabilizing surface elements, the bottom surface of the core being attached to the first stabilizing surface element and the top surface of the core being attached to the second stabilizing surface element, the core including a first section and a second section spaced-apart from the first section to form an elongated gap therebetween, the first and second sections of the core being arranged so that the blank can be bent along the gap, each of the first and second sections of the core being attached to both the first and second unitary stabilizing surface elements.

RELATED APPLICATION

This application is a continuation-in-part of application Ser. No.08/495,323, filed Jun. 27, 1995, now U.S. Pat. No. 5,685,935 which is acontinuation of application Ser. No. 08/124,638, filed Sep. 22, 1993,now abandoned, the specification of which is herein incorporated byreference.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to caskets, and particularly to a blankthat can be formed into a lightweight casket suitable for cremation andinterment ceremonies. More particularly, the present invention relatesto a generally planar blank that can be easily shipped and can bereadily formed into a body containment portion of a casket suitable forreceiving the remains of the deceased. The present invention alsorelates to a casket lid for covering the body containment portion of thecasket.

The disposal of the remains of the deceased can be accomplished byseveral means including burial and cremation. Providing a casket madefrom lightweight and inexpensive materials such as corrugated cardboardor the like for the disposal of such remains is known in the art. Forexample, U.S. Pat. Nos. 3,969,798 to Sahlin; 4,967,455 to Elder;5,353,484 to Woedl et al.; 4,944,076 to Kay et al.; 4,773,134 to Kay;and 4,730,370 to Elder as well as Japanese Publications Hei 31991!-198852, Hei 3 1991!-88517, Hei 4 1992!-3729, and Hei 4 1992!-3730to Takashi Makino all disclose caskets that can be made from lightweightmaterials.

In addition, it is known to construct a shell or base of a casket from aplanar blank sheet. For example, the Sahlin '798 patent, the Elder '455patent, the Woedl et al. '484 patent, and the Elder '370 patent alldisclose planer blank sheets suitable for being formed into a casket.What is needed is a lightweight casket that exhibits high strength toavoid structural failure during use, that is made from inexpensivematerials, and that is suitable for burial and cremation of the remainsof a deceased.

According to the present invention a blank is provided for folding intoa body containment portion of a casket. The blank includes a core havinga top surface and a bottom surface. The core is divided into a firstsection and a second section that is spaced apart from the first sectionto form an elongated gap therebetween. The blank further includes afirst stabilizing surface element positioned to lie beneath the core andattached to the bottom surfaces of the first and second sections of thecore.

The blank also includes a second stabilizing surface element that isattached to the top surface of the core. The second stabilizing surfaceelement has a bridge portion covering the gap between the first andsecond sections of the core so that the first section of the core, thesecond section of the core, the first stabilizing surface element, andthe bridge portion of the second stabilizing surface element cooperateto define an elongated space. The first stabilizing surface element andthe bridge portion are both bendable adjacent to the space so that theblank can be bent along the space.

The longitudinally extending core can be made from either a closed-cellmaterial or an open-cell material. In preferred embodiments, the core isan open-cell material having a plurality of cylindrically shaped cells.The walls of the cylindrically shaped cells extend in a direction thatis generally perpendicular to the first and second stabilizing surfaceelements. Typically, the cells are interconnected and are arranged toform a honeycomb pattern.

The core cooperates with the stabilizing surface elements to provide theblank and the casket made therefrom with structural rigidity. The corematerial operates to resist shear forces so that caskets made from suchsandwiched blanks can be carried without buckling. At the same time, thestabilizing surface elements resist the bending forces acting on thesandwich. While the first and second stabilizing surface elementscooperate with the core to cause the blank to resist bending, the spacebetween the first and second sections of the core provides a selectedarea along which the blank may be bent when forming the blank into abody containment portion of a casket.

The second stabilizing surface element covers the entire top surface ofthe core of the blank as well as covering the space between the firstand second sections of the core. When the blank is formed into the bodycontainment portion, the second stabilizing surface element becomes acontinuous, seamless inner wall for the lightweight casket.

Additionally, the second stabilizing surface element can be providedwith a coating of a water repellent material that prevents thepenetration of water through the second stabilizing surface element. Theseamless and waterproof inner wall of the casket prevents liquids thatmay collect on the second stabilizing surface element from seepingthrough the casket walls and passing out of the casket.

In addition, the core of the blank in accordance with the presentinvention is typically arranged so that once the blank is folded into abody containment portion, core material is present to reinforce thebottom of the casket, the two spaced-apart elongated sides of thecasket, and the two transverse ends of the casket. Also, supportinserts, rails, and stiffeners that may be desired for the bodycontainment section or for a lid of the casket can be formed to includea core having first and second opposing surfaces, a stabilizing surfaceelement attached to the first surface, and the second surface attachedto the body containment section or the lid of the casket.

Additional objects, features, and advantages of the invention willbecome apparent to those skilled in the art upon consideration of thefollowing detailed description of the preferred embodiments exemplifyingthe best mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the accompanying figuresin which:

FIG. 1 is a perspective view of a lightweight casket constructed inaccordance with the principles of the present invention showing abox-shaped body containment portion and a lid covering the bodycontainment portion;

FIG. 2 is a view taken along line 2 of FIG. 1 with portions broken awayshowing the placement of various layers used in the construction of thecasket;

FIG. 3 is a perspective view of a portion of a first embodiment of ablank in accordance with the present invention used to construct alightweight casket showing a core having first, second, and thirdspaced-apart sections positioned to lie above and attached to a firststabilizing surface element;

FIG. 3a is a perspective view with portions broken away of a blank inaccordance with the present invention showing a first stabilizingsurface element above and attached to a decorative layer, a secondstabilizing surface element spaced-apart from and generally parallel tothe first stabilizing surface element, and a core made from aclosed-cell material such as polystyrene foam sandwiched between thefirst and second stabilizing surface elements;

FIG. 4 is a view similar to FIG. 3 showing the blank including the firststabilizing surface element, the first, second, and third spaced-apartsections of the core, and the second stabilizing surface elementattached to the top surface of the core;

FIG. 4a is an enlarged view taken along line 4a--4a of FIG. 4 showingthe first stabilizing surface element attached to an underlying sheet ofdecorative material, two spaced-apart core sections forming a gaptherebetween and positioned to lie above the first stabilizing surfaceelement, and a second stabilizing surface element attached to a topsurface of the core, the second stabilizing surface element including abridge portion bridging the gap between the core sections so that thefirst stabilizing surface element cooperates with the core sections andthe bridge portion to define a space;

FIG. 5 is a view similar to FIG. 4 showing the blank including anadditional layer of core attached to the second stabilizing surfaceelement and a third stabilizing surface element attached to theadditional layer of core;

FIG. 5a is a view taken along line 5a--5a of FIG. 5 showing theadditional layer of core attached to the second stabilizing surfaceelement and the third stabilizing surface element attached to theadditional layer of core;

FIG. 6 is a view of the blank of FIG. 5 showing the blank after afolding stage;

FIG. 7 is an exploded perspective view of the blank of FIG. 6 after anadditional folding step to form a body containment portion of a casket,showing end inserts which are inserted adjacent to ends of the bodycontainment portion;

FIG. 8 is a view similar to FIG. 7 of a body containment portion of alightweight casket formed from the blank of FIG. 5 showing a layer ofdecorative material and the first stabilizing surface element forming anouter shell of the body containment portion, a core attached to thefirst stabilizing surface element, a second stabilizing surface elementattached to a top surface of the core and forming an inner wall of thebody containment portion, and the third stabilizing surface elementforming a bottom of the casket and attached to the additional layer ofcore (not shown);

FIG. 9 is a sectional view taken along line 9--9 of FIG. 8 showing thedecorative material and the first stabilizing surface element forming anouter shell of the lightweight casket, the core reinforcing the sidesand the bottom of the casket, the additional layer of core reinforcingthe bottom of the body containment portion, and the second stabilizingsurface element forming a seamless inner wall of the body containmentportion;

FIG. 10 is a view similar to FIG. 3 of a second embodiment of a blank inaccordance with the present invention used to construct a lightweightcasket showing a first-stabilizing surface element above and attached toa decorative layer and a core having first, second, third, fourth, andfifth spaced-apart sections positioned to lie above and attached to thefirst stabilizing surface element;

FIG. 11 is a view similar to FIG. 10 showing a second stabilizingsurface element attached to a top surface of the core and covering eachof the first, second, third, fourth, and fifth sections of the core aswell as covering the spaces formed therebetween;

FIG. 12 is a view of the blank of FIG. 11 showing the blank after afolding stage;

FIG. 13 is a view similar to FIG. 12 showing the blank after anadditional folding step to form a body containment portion of a casket;

FIG. 14 is a view similar to FIG. 10 of a third embodiment of a blank inaccordance with the present invention used to construct a lightweightcasket showing a first stabilizing surface element above and attached toa decorative layer and a core having first, second, third, fourth,fifth, sixth, and seventh spaced-apart sections positioned to lie aboveand attached to the first stabilizing surface element;

FIG. 15 is a view similar to FIG. 14 showing a second stabilizingsurface element attached to a top surface of the core and covering eachof the first, second, third, fourth, fifth, sixth, and seventhspaced-apart sections of the core as well as covering the spaces formedtherebetween;

FIG. 16 is a view of the blank of FIG. 15 showing the blank after afolding stage;

FIG. 17 is a view similar to FIG. 16 showing the blank after anadditional folding step to form a body containment portion of a casket;

FIG. 18a is an exploded perspective view of a casket lid and of a jigfor forming the casket lid showing the jig positioned to lie beneathelements of the lid, the jig cover being in an open position, and a3-piece first lid stabilizing surface element positioned to lie beneatha lid core and a second lid stabilizing surface element, the lid corebeing sandwiched between the lower first and upper second lidstabilizing surface elements, a stabilizing bar including a bar corebeing attached to the perimeter edge of the first lid stabilizingsurface element;

FIG. 18b is a view similar to FIG. 18a of a second embodiment of thefirst lid stabilizing surface element showing a unitary lid stabilizingsurface element formed to include slits and cut-away portions configuredto permit shaping of the lid stabilizing surface element;

FIG. 18c is a view similar to FIG. 18a of a "cut-top" casket lid showinga cut-top first lid stabilizing surface element positioned to liebeneath a cut-top lid core and a cut-top second lid stabilizing surfaceelement;

FIG. 19 is a perspective view of the jig with the jig cover in the openposition;

FIG. 20 is a perspective view of the jig with the jig cover in theclosed position showing an air pressure connector mounted on the jigcover; and

FIG. 21 is a sectional view taken along lines 21--21 of FIG. 20 showingthe jig and the lid during formation of the lid.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in detail wherein like reference numeralshave been used throughout the various figures to designate likeelements, there is shown in FIG. 1 a perspective view of the lightweightcasket constructed in accordance with the principles of the presentinvention and designated generally as 10. Casket 10 is comprisedessentially of body containment portion 12 and lid section 14. As shownin FIG. 2 for body containment portion 12, it is comprised largely ofopen cell core section 16, preferably a honeycomb pattern, beingsandwiched between a first stabilizing surface element 18 and a secondstabilizing surface element 20, both of which are preferably formed froma fluid resistant material. Lid 14 is constructed in a similarly layeredmanner.

The formation of body containment portion 12 from a blank 13 isaccomplished in part as shown in FIG. 3. Core 16 is cut to asubstantially rectangular shape and of a size adapted to be folded toform casket 10. Core 16 includes a top surface 17, a bottom surface (notshown) attached to first stabilizing surface element 18. In addition,core 16 includes a first section 16a, a second section 16b that isspaced apart from first section 16a to form a longitudinal space 30atherebetween, and a third section 16c that is spaced-apart from firstsection 16a to form a second longitudinal space 30b therebetween.

In forming body containment portion 12, first stabilizing surfaceelement 18 is placed underneath core 16 as shown in FIG. 3 and isattached to the bottom surface (not shown) of core 16. Secondstabilizing surface element 20 is placed on top of core 16, as shown inFIG. 4, and is attached to top surface 17 of core 16.

First stabilizing surface element 18 is larger in length than coresection 16 and is substantially rectangular in shape. First stabilizingsurface element 18 is cut along four lines 24a, 24b, 24c, 24d, as shownin FIG. 3, and is scored to include fold lines 23a, 23b that arepreferably arranged as continuations of cuts 24a, 24b, 24c, 24d. Foldlines 23a, 23b and cuts 24a, 24b, 24c, 24d facilitate the folding ofblank 13 including core 16 and first stabilizing surface element 18attached thereto into body containment portion 12 as shown in FIGS. 6, 7and 8. Fold lines 23a, 23b are longitudinal and extend along the lengthof spaces 30a, 30b and cuts 24a, 24b, 24c, 24d extend from fold lines23a, 23b to the ends of first stabilizing surface elements 18.

Core 16 is preferably formed from polymer coated cellulose fiber (PCCF)but environmentally safe plastic or the like will also suffice. Core 16is preferably comprised of a plurality of longitudinally extendingcylindrically shaped cells 25 interconnected and forming a honeycombpattern as shown in FIGS. 3 and 4. Because of their cylindrical shape,the members have strong structural rigidity along their longitudinalaxes.

Core 16 is adhered to the upper surface of scored and cut firststabilizing surface element 18 utilizing any suitable adhesive. Inaddition, a sheet 26 of decorative material is adhered to the undersideof first stabilizing surface element 18 for incorporating a desiredtexture and appearance to casket 10 as shown in FIG. 3a.

Second stabilizing surface element 20 is similarly adhered to core 16 asshown in FIG. 4. Second stabilizing surface element 20 is preferably aunitary sheet including bridge portions 22a, 22b that cover spaces 30a,30b and that bridge spaces 30a, 30b between first and second sections16a, 16b of core 16 and between first and third sections 16a, 16c ofcore 16 as shown in FIGS. 4 and 4a. Second stabilizing surface element20 is scored with fold lines 23c, 23d along bridge portions 22a, 22b tofacilitate folding of blank 13 after second stabilizing surface element20 is attached thereto. Fold lines 23c, 23d are longitudinal and arepositioned to lie generally above fold lines 23a, 23b and extend alongthe length of spaces 30a, 30b to divide second stabilizing surfaceelement 20 into a first section 28a, a third section 28c, and a centersecond section 28b therebetween.

Core 16 is sandwiched between first and second stabilizing surfaceelements 18, 20 as shown in FIGS. 4 and 4a to provide structuralrigidity to core 16 by maintaining cells 25 of core 16 in asubstantially perpendicular orientation to applied forces. Core 16 actsas a pressure transfer mechanism and transfers the load to outerstabilizing surface element 18 when a force is applied thereto. Byforming spaces 30a, 30b between sections 16a, 16b, 16c of core 16, blank13 adjacent to spaces 30a, 30b lacks the structural rigidity of theportions of blank 13 engaging core 16 and having the complete sandwichstructure. The "open" and, therefore, weaker sections of blank 13adjacent to spaces 30a, 30b can be bent to form body containment portion12 as shown in FIGS. 6 and 7.

In addition to core 16, an additional layer of core 32 can be attachedto blank 13 over center section 28b of second stabilizing surfaceelement 20, as shown in FIGS. 5 and 5a. Additional layer of core 32 ispreferably of substantially the same size as center portion 28b. Also, athird stabilizing surface element 34 is typically attached to the top ofadditional layer of core 32. Additional layer of core 32 and thirdstabilizing surface element 34 further strengthen and increase thestructural rigidity of the casket bottom and provide extra structuralsecurity.

Blank 13 as shown in FIG. 5 is complete and is ready for formation intobody containment portion 12. To initiate this process, sides 36a, 36b ofblank 13 are folded upwardly along fold lines 23a, 23b, 23c, 23d and cutlines 24a, 24b, 24c, 24d adjacent to spaces 30a, 30b. Upon folding sides36a, 36b, corners 38a, 38b, 38c, 38d must be folded inward towards thecenter of body containment portion 12 as shown in FIG. 6. Corners 38a,38b, 38c, 38d thus become part of the ends of body containment portion12. However, the ends are further completed by folding end extensions40a, 40b upwardly toward folded corners 38a, 38b, 38c, 38d. Beforefolding extensions 40a, 40b, adhesive is applied on the contact surfacesthereof for adherence to the outside surfaces of folded corners 38a,38b, 38c, 38d. This provides a double shear path and increases thestrength of the enclosure.

Referring now to FIG. 7, body containment portion 12 is ready for theinsertion of end inserts 42a, 42b. Each end insert 42a, 42b is comprisedof a rectangular portion of core material and a stabilizing surfaceelement 44a, 44b adhered thereto as shown in FIGS. 7 and 8. Stabilizingsurface elements 44a, 44b are adhered to inner surfaces of end inserts42a, 42b facing the inside of body containment portion 12. End inserts42a, 42b are inserted adjacent each end of body containment portion 12.The side of each end insert 42a, 42b having no stabilizing surfaceelement adhered thereto is placed adjacent and adhered to inner surfacesof the folded corners 38a, 38b, 38c, 38d. End insert 42a is adhered tofolded corners 38a, 38d and end insert 42b is adhered to folded corners38b, 38c. At this point in the construction process body containmentportion 12 is fully constructed as shown in FIG. 8.

Second stabilizing surface element 20 is preferably a unitary sheet asshown in FIG. 4 covering the entire top surface of core 16. After blank13 is folded to form body containment portion 12 shown in FIG. 8, secondstabilizing surface element 20 provides a seamless inner wall forlightweight casket 10. The material of second stabilizing surfaceelement 20 comprising bridge portions 22a, 22b collapses outwardly intospaces 30a, 30b upon folding of sides 36a, 36b of blank 13 as shown inFIG. 9.

A second embodiment of a blank 213 and a body containment portion 212formed therefrom is shown in FIGS. 10-13. Illustratively, a firststabilizing surface element 218 includes a generally centrally locatedcenter section 218a, a first side section 218b adjacent thereto andseparated from center section 218a by scored fold line 223a, and asecond side section 218c adjacent to center section 218a and separatedtherefrom by scored fold line 233b as shown in FIG. 10. Additionally,first stabilizing surface element 218 includes a first end section 218dand a second end section 218e. First end section 218d includes twocorners 238a, 238d and a center portion 218f separated from corners238a, 238d by fold lines 223a, 223b. Center portion 218f is separatedfrom center section 218a by a scored fold line 223c and corners 238a,238d are separated from side sections 218c, 218b by cut lines 224c,224d. Second end section 218e likewise has two corners 238b, 238c and acenter portion 218g separated from corners 238b, 238c by fold lines223a, 223b. Center portion 218g is separated from center 218a by ascored fold line 223d and corners 238b, 238c are separated from sidesections 218c, 218b by cut lines 224b, 224a.

Blank 213 also includes a core 216 having a top surface 217 and a bottomsurface (not shown). A generally centrally located first core section216a of core 216 is attached to center section 218a, a second coresection 216b is attached to first side section 218b and spaced apartfrom first core section 216a to form a first space 230a therebetween,and a third core section 216c is attached to second side section 218cand spaced apart from first core section 216a to form a second space230b therebetween as shown in FIG. 10. Core 216 also includes a fourthcore section 216d attached to first end section 218d and spaced apartfrom first core section 216a to form a third space 230c therebetween anda fifth core section 216e attached to second end section 218e and spacedapart from first core section 216a to form a fourth space 230dtherebetween. Preferably, fourth core section 216d is attached to centerportion 218f of first end section 218d and fifth core section 216e isattached to center portion 218g of second end section 218e.

A second stabilizing surface element 220 is attached to top surface 217of core 216 and is configured to cover the entire top surface 217 ofcore 216 as shown in FIG. 11. Preferably, second stabilizing surfaceelement 220 is unitary and seamless. Second stabilizing surface element220 includes a scored first fold line 223e adjacent to first space 230a,a scored second fold line 223f adjacent to second space 230b, a scoredthird fold line 223g adjacent to third space 230c, and a scored fourthfold line 223h adjacent to fourth space 230d. Preferably, first andsecond fold lines 223e, 223f are generally parallel, and third andfourth fold lines 223g, 223h are generally parallel to one another andare generally perpendicular to first and second fold lines 223e, 223f.

Blank 213 can include an additional layer of core (not shown) attachedto second stabilizing surface element 220 over center core section 216a.Blank 213 can also include a third stabilizing surface element (notshown) attached to a top surface of the additional layer of core. Theadditional layer of core and the third stabilizing surface element canfurther strengthen and increase the structural rigidity of the casketbottom and provide extra structural security thereto.

To form blank 213 into a body containment portion 212, sides 236a, 236bare folded upwardly along fold lines 223e, 223f formed on secondstabilizing surface element 220, spaces 230a, 230b, and fold lines 223a,223b on first stabilizing surface element 218, and separating along cutlines 224a, 224b, 224c, 224d on first stabilizing surface element 218.First and second end sections 218d, 218e are folded upwardly along foldlines 223c, 223d shown in FIG. 10 and fold lines 223g, 223h shown inFIG. 12. Corners 238a, 238b, 238c, 238d are folded inwardly toward thecenter of body containment portion 212 as shown in FIG. 13. Beforefolding corners 238a, 238b, 238c, 238d, adhesive is applied on thecontact surfaces thereof for adherence to decorative material 226attached to the bottom of first stabilizing surface element 218. At thispoint in the construction process, blank 213 is fully constructed andformed into a second embodiment of body containment portion 212 oflightweight casket 210 as shown in FIG. 13.

A third embodiment of a blank 313 and a body containment portion 312formed therefrom is shown in FIGS. 14-17. Illustratively, a firststabilizing surface element 318 includes a generally centrally locatedcenter section 318a, a first side section 318b adjacent thereto andseparated from center section 318a by a scored fold line 323a, and asecond side section 318c adjacent to center section 318a and separatedtherefrom by a scored fold line 323b, as shown in FIG. 14. Additionally,first stabilizing surface element 318 includes a first end section 318dseparated from center section 318a and side sections 318b, 318c by ascored fold line 323c and a second end section 318e separated fromcenter section 318a and side sections 318b, 318c by a scored fold line323d. First end section 318d has two corners 338a, 338d and a centerportion 318f separated from corners 338a, 338b by cut lines 324c, 324d.Second end section 318e has two corners 338b, 338c and a center portion318g separated from corners 338b, 338c by cut lines 324b, 324a.

Blank 313 also includes a core 316 having a top surface 317 and a bottomsurface (not shown). A generally centrally located first core section316a of core 316 is attached to center section 318a, a second coresection 316b attached to first side of section 318b and spaced apartfrom first core section 316a to form a first space 330a therebetween,and a third core section 316c is attached to second side section 318cand spaced apart from first core section 316a to form a second space330b therebetween as shown in FIG. 14. Core 316 also includes a fourthcore section 316d attached to corner 338d of first end section 318d andspaced apart from second core section 316b to form a third space 330ctherebetween, a fifth core section 316e attached to corner 338a of firstend section 318d and spaced apart from third core section 316c to form afourth space 330d therebetween. Additionally, core 316 includes a sixthcore section 316f attached to corner 338c of second end section 318e andspaced apart from second core section 316b to form a fifth space 330etherebetween and a seventh core section 316g attached to corner 338b ofsecond end section 318e and spaced apart from third core section 316c toform a sixth space 330f therebetween.

A second stabilizing surface element 320 is attached to top surface 317of core 316 and is configured to cover the entire top surface 317 ofcore 316 as shown in FIG. 15. Preferably, second stabilizing surfaceelement 320 is unitary and seamless. Second stabilizing surface element320 includes a scored first fold line 323g adjacent to first space 330a,a scored second fold line 323h adjacent to second space 330b, a scoredthird fold line 323i adjacent to space 330c, a scored fourth fold line323j adjacent to space 330d, a scored fifth fold line 323k adjacent tospace 330e, and a scored sixth fold line 323l adjacent to space 330f.Preferably, first and second fold lines 323g, 323h are generallyparallel, and third, fourth, fifth, and sixth fold lines 323i, 323j,323k, 323l are generally parallel to one another and generallyperpendicular to first and second fold lines 323g, 323h.

Blank 313 can include an additional layer of core (not shown) attachedto second stabilizing surface element 320 over center core section 316a.Blank 313 can also include a third stabilizing surface element (notshown) attached to a top surface of the additional layer of core. Theadditional layer of core and the third stabilizing surface element canfurther strengthen and increase the structural rigidity of the casketbottom and provide additional structural security thereto.

To form blank 313 into a body containment portion 312, sides 336a, 336bare folded upwardly along fold lines 323g, 323h formed on secondstabilizing surface element 320, spaces 330a, 330b, fold lines 323a,323b on first stabilizing surface element 318, and cut lines 324a, 324b,324c, 324d on first stabilizing surface element 318. After folding sides336a, 336b, corners 338a, 338b, 338c, 338d are folded inwardly towardthe center of body containment portion 312 along fold lines 323i, 323j,323k, 323l, and spaces 330c, 330d, 330e, 330f as shown in FIG. 16 sothat corners 338a, 338b, 338c, 338d become part of the ends of bodycontainment portion 312 as shown in FIG. 16. The ends of bodycontainment portion 312 are further completed by folding center portion318f of end 318d and center portion 318g of end 318e upwardly to engagefolded corners 338a, 338b, 338c, 338d. Before folding center portions318f of first end section 318b and second end section 318e, adhesive isapplied on the contact surfaces thereof for adherence to the outsidesurfaces of folded corners 338a, 338b, 338c, 338d. At this point in theconstruction process, blank 313 is fully constructed and formed into thethird embodiment of body containment portion 312 of lightweight casket310 as shown in FIG. 17.

Lid 14 of lightweight casket 10 is fabricated as shown in FIGS. 18a-21.Lid 14 is formed by placing a lid core 46 preferably comprised of ahoneycomb material between two lid stabilizing surface elements 48a, 48bas shown in FIG. 18a. The construction of lid 14 requires a somewhatdifferent process than the construction of the body containment portion12 due to the curved shaped of lid 14. The preferred method ofconstructing lid 14 is to construct a jig 50 having an outer portionresembling the shape of lid 14. Jig 50 is used to construct lid 14 in astep-like manner which includes the application of a pressure source 52.

Jig 50 has an outer section 51 shown in FIG. 18a which is substantiallyin the shape of lid 14 shown in FIG. 1. To initiate the lid constructionprocess, first stabilizing surface element 48a is placed into jig 50. Asshown in FIG. 18a, first stabilizing surface element 48a is constructedfrom one to three separate elements, a center element and twotriangularly-shaped end elements. These elements are placed into jig 50.Each of the elements has an edge 54a, 54b, 54c, 54d formed into arectangular shape and adapted to receive perimeter stabilizing bars 56a,56b, 56c, 56d. Perimeter stabilizing bars 56a, 56b, 56c, 56d form theportion of lid 14 which contacts body containment portion 12, 212, 312.It is important that the edges which contact body containment portion12, 212, 312 have structural rigidity as well as lid 14 itself.Therefore, bars 56a, 56b, 56c, 56d are placed into folded edges 54a,54b, 54c, 54d and secured therein by adhering edges 54a, 54b, 54c, 54dthereto.

Each bar 56a, 56b, 56c, 56d includes a bar core 56e made from honeycombmaterial as shown in FIG. 18a, although each bar 56a, 56b, 56c, 56d canbe made from any material that provides structural stability to lid 14such as metal, wood, and particle board without changing the scope ofthe invention as presently perceived. Preferably, edges 54a, 54b, 54c,54d include stabilizing surface element portions 55a, 55b, 55c, 55dconnected to oppposing top and bottom surfaces of bar core 56e. Havingedges 54a, 54b, 54c, 54d formed into an elongated rectangular shape andsurrounding each bar core 56e provides additional strength and securityto lid 14.

Lid core 46 is placed into jig 50 and over first stabilizing surfaceelement 48a as shown in FIG. 18a. Preferably, lid core 46 is made fromthe same material as core 16, 216, 316 of body containment portion 12,212, 312. Prior to the insert of lid core 46 into jig 50, adhesive isspread over first stabilizing surface element 48a for causing lid core46 to adhere thereto. Lid core 46 is a substantially rectangular pieceof material which is cut to a size which conforms to the shape of lid 14and still contacts the entire surface of first stabilizing surfaceelement 48a. It is not necessary to cut or provide fold lines in lidcore 46 in any manner due to the flexibility of the same in conformingto the general shape of lid 14.

With lid core 46 inserted therein, second stabilizing surface element48b is placed over the top of inserted lid core 46. Second stabilizingsurface element 48b is rectangular but is comprised of an odd shapedsection 58 having triangularly shaped but integral end sections 59a, 59band having angular fold cuts as shown in FIG. 10. These sections 58,59a, 59b are placed on lid core 46 as shown in FIG. 18a and conform tojig 50. Prior to placement onto lid core 46, adhesive is applied to theside of the sections which will contact lid core 46. With all elementsin place, a pressure source 52 is applied to the integrated sections.

As shown in FIGS. 19 and 20, a flexible cover 60 is hinged to andextends from the edges of jig 50 via a hinged door 61 and is placed overthe integrated elements just discussed, forming an air tight seal. Apressure source connector 62 extends from flexible portion 60 so as toconnect pressure source 52 thereto. Accordingly, pressure source 52 isconnected to connector 62 and pressure is applied to lid 14. Thepressure thereby forces the integrated sections together for adheringthose which are contacting each other and forcing them into the shape ofjig 50. In addition, a decorative layer 64 can be applied to lid 14 formatching body containment portion 12. When the air is removed and thesections are adhered together, jig 50 is disassembled and lid 14 can beremoved, resembling the configuration shown in FIG. 1.

Lid 14 can alternatively include a unitary first lid stabilizing surfaceelement 48a as shown in FIG. 18b. Unitary first lid stabilizing surfaceelement 48a is formed to include slits 72 extending inwardly from thecorners of first lid stabilizing surface element 48a and terminating inscore lines 70 that angle inwardly in generally the same direction aseach respective slit. The width of slits 72 is greatest adjacent to thecorners and narrows gradually inwardly toward score lines 70. Scorelines 70 and slits 72 define generally triangularly-shaped but integralend sections 74a, 74b of unitary first lid stabilizing surface element48a. Score lines 70 and slits 72 cooperate to allow end sections 74a,74b to move in jig 50 so that lid 14 can assume the desired shape.

Lid 14 can also be formed in separate halves providing a "cut-top lid"which is desirable for viewing purposes. The formation of lid 14 intotwo separate halves is performed essentially the same as described abovewith reference to FIGS. 18a and 18b except that each half is constructedseparately in jig 50 such that finished edges are formed all around asshown in FIG. 18c. When lid 14 is formed in separate halves, lid 14includes cut-top first lid stabilizing surface elements 48a, cut-topsecond lid stabilizing surface elements 48b, and cut-top cores 46sandwiched therebetween.

For both body containment portion 12 and lid 14, materials and patternsother than PCCF arranged in a honeycomb pattern can be used. Forexample, core 16, 32, 216, 316 can be comprised of an environmentallysafe polystyrene-type material 65 in lieu of the honeycomb materialwhere it is placed between two stabilizing surface elements as shown inFIG. 3a. Polystyrene foam placed between similar stabilizing surfaceelements exhibits substantially the same structural rigidity as thehoneycomb portions and can be used interchangeably. Additionally, PCCFand other materials can be formed into truss patterns which also exhibithigh structural rigidity when sandwiched between the stabilizing surfaceelements.

Upon completion of body containment portion 12, 212, 312 and lid 14 assubstantially described, lightweight casket 10, 210, 310 is finished byattaching ornamental elements thereto to give casket 10, 210, 310 aricher appearance. As shown in FIG. 1, preformed corner pieces 66a, 66b,66c, 66d are placed onto the corners of lightweight casket 10. Inaddition to appearance, corners 66a, 66b, 66c, 66d provide extrastrength in body containment portion 12, 212, 312. Corners 66a, 66b,66c, 66d are comprised substantially of two triangularly-shaped elementsattached perpendicularly to each other. Corners 66a, 66b, 66c, 66d canbe covered with the same decorative material as the rest of lightweightcasket 10, 210, 310. Corners 66a, 66b, 66c, 66d can be simply glued tobody containment portion 12, 212, 312 corners as shown in FIG. 1. Inaddition to the corners 66a, 66b, 66c, 66d, handles 68 can be securelyattached to each side of lightweight casket 10 for carrying of the same.The inner portion of lightweight casket 10 in its finished condition isalso designed in a decorative manner having linings and pillows.

Lightweight casket 10, 210, 310 is used in a manner similar to any othercasket. Because of the structural rigidity providing by the sandwichingof either the open cell or solid surface core materials betweenstabilizing surface elements, there are no special precautions whichmust be considered in handling lightweight casket 10, 210, 310. Theremains of the deceased are simply placed in casket 10, 210, 310 as withany other casket and it can be carried similar to any other casket. Forcremation purposes, casket 10, 210, 310 is highly flammable and, asdiscussed, is not harmful to the environment and can simply be placedinto the furnace without alteration.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof andaccordingly reference should be made to the appended claims rather thanto the foregoing specification as indicating the scope of the invention.

I claim:
 1. A blank for folding into a body containment section of acasket, the blank comprising:a first stabilizing surface element, thefirst stabilizing surface element being a unitary element, a secondstabilizing surface element positioned to lie above the firststabilizing surface element and spaced-apart therefrom, the secondstabilizing surface element being a unitary element, and a core having atop surface and a bottom surface, the core being sandwiched between thefirst and second stabilizing surface elements, the bottom surface of thecore being attached to the first stabilizing surface element and the topsurface of the core being attached to the second stabilizing surfaceelement, the core including a first section and a second sectionspaced-apart from the first section to form an elongated gaptherebetween, the first and second sections of the core being arrangedso that the blank can be bent along the gap, each of the first andsecond sections of the core being attached to both the first and secondunitary stabilizing surface elements.
 2. The blank of claim 1, whereinthe second stabilizing surface element includes a bridge portioncovering the gap between the first and second sections of core.
 3. Theblank of claim 2, wherein the bridge portion of the second stabilizingsurface element is formed to include an elongated scored fold line abovethe gap.
 4. The blank of claim 3, wherein the first stabilizing surfaceelement is formed to include an elongated scored fold line beneath thegap and adjacent to the scored fold line on the bridge portion.
 5. Theblank of claim 1, wherein the core further includes a third sectionspaced apart from the second section to form a second gap therebetween,the second stabilizing surface element further including a second bridgeportion covering the second gap, the second and third sections of thecore being arranged so that the blank can be bent along the second gap.6. The blank of claim 5, wherein the second bridge portion of the secondstabilizing surface element is formed to include a second scored foldline above the second gap.
 7. The blank of claim 5, wherein the first,second, and third sections are rectangular planar sections and thesecond section is positioned to lie between the first and thirdsections.
 8. The blank of claim 1, further comprising an additionallayer of core having a top surface and a bottom surface, the bottomsurface of the additional layer of core being attached to the secondstabilizing surface element, and a third stabilizing surface elementattached to the top surface of the additional layer of core.
 9. Theblank of claim 8, wherein the additional layer of core is sized to havesubstantially the same area and is substantially the same shape as thesecond section of the second stabilizing surface element, the bottomsurface of the additional layer of core is attached to the secondsection of the second stabilizing surface element, and the thirdstabilizing surface element is sized to have substantially the same areaand is substantially the same shape as the additional layer of core. 10.The blank of claim 1, wherein the core comprises an open-celledmaterial.
 11. The blank of claim 10, wherein each cell of theopen-celled material includes a wall that is positioned to lie inorthogonal relation to the first and second stabilizing surfaceelements.
 12. The blank of claim 11, wherein the cells are cylindricallyshaped cells and the core includes a plurality of such cellsinterconnected and forming a honeycomb pattern.
 13. The blank of claim1, wherein the core comprises a closed-cell material.
 14. The blank ofclaim 13, wherein the closed-cell material is polystyrene foam.
 15. Theblank of claim 1, further comprising a decorative material attached tothe underside of the first stabilizing surface element.
 16. The blank ofclaim 1, wherein the second stabilizing surface element covers theentire top surface of the core.
 17. The blank of claim 16, wherein thesecond stabilizing surface element includes a coating made from ahydrophobic material to prevent the penetration of aqueous-based liquidsthrough the second stabilizing surface element.
 18. The blank of claim1, wherein the first stabilizing surface element covers the entirebottom surface of the core.
 19. The blank of claim 18, wherein the firststabilizing surface element includes a coating made from a hydrophobicmaterial to prevent the penetration of aqueous-based liquids through thefirst stabilizing surface element.
 20. The blank of claim 1, wherein asupport plate is attached to the first stabilizing surface elementadjacent to the gap between the first and second sections of the core.21. The blank of claim 20, wherein the support plate includes an insertcore having a top surface and a bottom surface, an insert stabilizingsurface element attached to the top surface of the insert core, thebottom surface of the insert core being attached to the firststabilizing surface element.
 22. A blank for folding into a bodycontainment section of a casket, the blank comprising:an elongated firststabilizing surface element having a generally centrally located centersection with first and second longitudinally extending transverselyspaced-apart sides and first and second transversely extending,longitudinally spaced-apart ends, a first end section appended to thefirst end of the center section, a second end section appended to thesecond end of the center section, a first side section appended to thefirst side of the center section, and a second side section appended tothe second side of the center section, each of the first and second endsections and first and second side sections being foldable relative tothe center section, the first stabilizing surface element being aunitary element, a core having a top surface and a bottom surface, thecore being positioned to lie above the first stabilizing surface elementand the bottom surface of the core being attached thereto, the coreincluding a first section attached to the center section of the firststabilizing surface element, a second section attached to the first sidesection of the first stabilizing surface element, the second sectionbeing spaced apart from the first section to form a first spacetherebetween, and a third section attached to the second side section ofthe first stabilizing surface element, the third section being spacedapart from the first section to form a second space therebetween, and asecond stabilizing surface element attached to the top surface of thecore, the second stabilizing surface element including a first bridgeportion covering the first space formed between the first and secondsections and a second bridge portion covering the second space formedbetween the first and third sections, the second stabilizing surfaceelement being a unitary element.
 23. The blank of claim 22, furthercomprising a fourth section of the core positioned to lie on the firstend section and a fifth section of the core positioned to lie on thesecond end section.
 24. The blank of claim 23, wherein each of the firstand second end sections of the first stabilizing surface elementincludes a first side portion adjacent to the first side section of thefirst stabilizing surface element, a second side portion adjacent to thesecond side section of the first stabilizing surface element, and acenter portion therebetween, the fourth section of the core is attachedto the center portion of the first end section, and the fifth section ofthe core is attached to the center portion of the second end section.25. The blank of claim 23, wherein each of the first and second endsections of the first stabilizing surface element includes a first sideportion adjacent to the first side section of the first stabilizingsurface element, a second side portion adjacent to the second sidesection of the first stabilizing surface element, and a center portiontherebetween, the fourth section of the core is attached to the firstside portion of the first end section, and the fifth section of the coreis attached to the first side portion of the second end section.
 26. Theblank of claim 25, further comprising a sixth section of the coreattached to the second side portion of the first end section and aseventh section of the core attached to the second side portion of thesecond end section.
 27. The blank of claim 2, wherein the bridge portionis elongated and covers the entire gap.
 28. The blank of claim 2,wherein the bridge portion folds into the gap and toward the firststabilizing surface element when the blank is bent along the gap. 29.The blank of claim 2, wherein the second stabilizing surface elementprovides the body containment portion with a seamless inner surfaceadjacent to the first and second sections of the core after the blank isfolded into the body containment portion.
 30. The blank of claim 5,wherein the first bridge portion is elongated and covers the entirefirst gap and the second bridge portion is elongated and covers theentire second gap.
 31. The blank of claim 5, wherein the first bridgeportion folds into the first gap and toward the first stabilizingsurface element when the blank is bent along the first gap and thesecond bridge portion folds into the second gap and toward the firststabilizing surface element when the blank is bent along the second gap.32. The blank of claim 5, wherein the second stabilizing surface elementprovides the body containment portion with a seamless inner surfaceadjacent to the first, second, and third sections of the core after theblank is folded into the body containment portion.